Integrated Aftertreatment System

ABSTRACT

Implementations described herein relate to features for an integrated aftertreatment system. In one implementation, an integrated aftertreatment system comprises a casing that includes a mating flange having a first constant diameter and a catalyst component configured to mate to the mating flange of the casing. The catalyst component includes a canned body including a first portion sized to a second constant diameter to mate with the first constant diameter of the mating flange. In another implementation, an integrated aftertreatment system comprises a casing, a catalyst component positioned within the casing, a particulate filter having an outer casing with an outlet, and a particulate filter joint coupled to the outer casing of the particulate filter at the outlet. An end of the particulate filter joint is aligned with an end of the particulate filter.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application claims priority to U.S. Provisional PatentApplication No. 62/137,706, filed Mar. 24, 2015 and the contents ofwhich are incorporated herein by reference.

TECHNICAL FIELD

The present application relates generally to the field of aftertreatmentsystems for internal combustion engines.

BACKGROUND

For internal combustion engines, such as diesel engines, nitrogen oxide(NO_(x)) compounds may be emitted in the exhaust. To reduce NO_(x)emissions, a SCR process may be implemented to convert the NO_(x)compounds into more neutral compounds, such as diatomic nitrogen, water,or carbon dioxide, with the aid of a catalyst and a reductant. Thecatalyst may be included in a catalyst chamber of an exhaust system,such as that of a vehicle or power generation unit. A reductant, such asanhydrous ammonia, aqueous ammonia, or urea is typically introduced intothe exhaust gas flow prior to the catalyst chamber. To introduce thereductant into the exhaust gas flow for the SCR process, an SCR systemmay dose or otherwise introduce the reductant through a dosing modulethat vaporizes or sprays the reductant into an exhaust pipe of theexhaust system up-stream of the catalyst chamber. The SCR system mayinclude one or more sensors to monitor conditions within the exhaustsystem.

SUMMARY

Implementations described herein relate to features for an integratedaftertreatment system.

One implementation relates to an integrated aftertreatment system havinga casing that includes a mating flange having a first constant diameterand a catalyst component configured to mate to the mating flange of thecasing. The catalyst component includes a canned body including a firstportion sized to a second constant diameter to mate with the firstconstant diameter of the mating flange.

In some particular implementations, the catalyst component includes acatalyst and a mat material. The mat material is positioned between thecatalyst and the canned body. The canned body includes a second portionsized to a third diameter that is based on a holding pressure exerted onthe catalyst by the mat material. In some implementations, the holdingpressure is based on a target gap bulk density for the mat material. Insome implementations, the third diameter is less than the secondconstant diameter. In some implementations, the third diameter has atolerance of ±3.4 mm. In some implementations, the canned body includesa third portion sized to the third diameter, and the first portion ispositioned between the second portion and the third portion. In someimplementations, the second portion of the canned body of the catalystcomponent is upstream of the first portion or downstream of the firstportion.

Another implementation relates to an integrated aftertreatment systemhaving a casing, a catalyst component positioned within the casing, aparticulate filter having an outer casing with an outlet, and aparticulate filter joint coupled to the outer casing of the particulatefilter at the outlet. An end of the particulate filter joint is alignedwith an end of the particulate filter.

In some particular implementations, the particulate filter jointincludes a bead. In some implementations, the particulate filter jointis welded to the outer casing of the particulate filter. In someimplementations, the particulate filter joint reduces an overall lengthof the integrated aftertreatment system relative to an integrated joint.

Yet another implementation relates to an integrated aftertreatmentsystem having a first casing, a first component positioned within thefirst casing, a second casing, a second component positioned within thesecond casing, and a flared ring fixedly coupled to the first casing ata first end and coupled to the second casing at a second end oppositethe first end. The flared ring having a constant diameter portionextending from the first end to a flared portion at the second end. Theflared ring also includes a sensor coupling fixed to the constantdiameter portion.

In some particular implementations, the sensor coupling is a pressurecoupling or temperature coupling. In some implementations, the firstcomponent is a diesel oxidation catalyst and the second component is aparticulate filter. In some implementations, the flared ring is weldedto an outer portion of the first casing.

Still another implementation relates to an integrated aftertreatmentsystem having a casing, a catalyst positioned within the casing, and asensor mount coupled to an outer portion of the casing.

In some implementations, the sensor mount may include an integratedsensor harness and module alignment component. The integrated sensorharness and module alignment component includes rigid attachment pointsto couple to the outer portion of the casing. In some implementations,the sensor mount may include two or more tiers. In some implementations,the sensor mount may include both attachment openings and a strapattachment channel.

Still a further implementation relates to an integrated aftertreatmentsystem having a casing, a catalyst positioned within the casing, and apressure sensor assembly coupled to the casing. The pressure sensorassembly includes a tapered tube coupled at a first end to a pressuresensor module and coupled at a second end to a coupling of the casing.The first end has a smaller diameter than the second end.

In some particular implementations, the tapered tube is configured todrain water out from the tapered tube.

A further implementation relates to an integrated aftertreatment systemhaving a casing, a catalyst positioned within the casing, and anelectrical connector having a sealant within a backshell of theelectrical connector.

In some particular implementations, the sealant is RTV. In someimplementations, the backshell of the electrical connector is formedfrom polyurethane.

Another implementation relates to a mold for sealing an electricalconnector from a curing mold material that includes a first cavity foran electrical wire and a second cavity for an electrical connector. Thesecond cavity includes an upper lip and a lower lip to form a smalltolerance opening between the first cavity and the second cavity whenthe mold is closed and the electrical wire is coupled to the electricalconnector.

In some particular implementations, the second cavity is formed from anupper removable component and a lower removable component, the upperremovable component including the upper lip and the lower removablecomponent including the lower lip.

BRIEF DESCRIPTION

The details of one or more implementations are set forth in theaccompanying drawings and the description below. Other features,aspects, and advantages of the disclosure will become apparent from thedescription, the drawings, and the claims, in which:

FIG. 1 is a block schematic diagram of an example selective catalyticreduction system having an example reductant delivery system for anexhaust system;

FIG. 2 is a perspective view of an example connector;

FIG. 3 is another perspective view of an example connector;

FIG. 4 is yet another perspective view of an example connector;

FIG. 5 is a perspective schematic view of an example sealed connectorbackshell;

FIG. 6 is a schematic view of a catalyst component and a mating flange;

FIG. 7 is a partial side cross-sectional view of a catalyst componentinserted into a mating flange with a variable diameter sizing;

FIG. 8 is partial side cross-sectional view and perspective view of aseparate joint ring for a DPF body;

FIG. 9 is a partial side cross-sectional view of a DOC and DPF with atransition portion between the components;

FIG. 10 is a partial side cross-sectional view of the DOC and DPF with asensor positioned in the transition portion between the components;

FIG. 11 is a perspective view of a separate flared ring having aconstant diameter for the sensor to be inserted into the transitionportion;

FIG. 12 is a perspective view of the separate flared ring attached tothe DPF body;

FIG. 13 is a side elevation view of an integrated sensor harness andmodule alignment component;

FIG. 14 is a front elevation view of the integrated sensor harness andmodule alignment component of FIG. 13;

FIG. 15 is a perspective view of a stackable sensor mount;

FIG. 16 is a front elevation view of the stackable sensor mount of FIG.15;

FIG. 17 is a perspective view of a combination bolt and/or strap mountedsensor table;

FIG. 18 is a perspective view of the combination bolt and/or strapmounted sensor table attached via a strap;

FIG. 19 is a perspective view of the combination bolt and/or strapmounted sensor table attached via bolts;

FIG. 20 is a side elevation view of a pressure sensor tubeconfiguration;

FIG. 21 is a perspective view of a tapered pressure sensor tubeconfiguration;

FIG. 22 is a perspective view of a mold for sealing an electricalconnector from a curing mold material;

FIG. 23A is a perspective view of an upper removable component for themold of FIG. 22 having an upper lip; and

FIG. 23B is a perspective view of a lower removable component for themold of FIG. 22 having a lower lip.

It will be recognized that some or all of the figures are schematicrepresentations for purposes of illustration. The figures are providedfor the purpose of illustrating one or more implementations with theexplicit understanding that they will not be used to limit the scope orthe meaning of the claims.

DETAILED DESCRIPTION

Following below are more detailed descriptions of various conceptsrelated to, and implementations of, methods, apparatuses, and systemsfor an integrated aftertreatment system. The various concepts introducedabove and discussed in greater detail below may be implemented in any ofnumerous ways, as the described concepts are not limited to anyparticular manner of implementation. Examples of specificimplementations and applications are provided primarily for illustrativepurposes.

I. Overview

In some systems, an integrated aftertreatment system may reduce the sizeof the system, decrease the costs by reducing the number of parts, andsimplify designing needs by having a consistent configuration andreducing the footprint of the system. An integrated aftertreatmentsystem may include a number of aspects including sealed electricalconnector backshells, variable sizing to facilitate catalyst retentionand welding of mating components, integrated sensor harness andaftertreatment system module alignment and sensor bracket locatingfeatures, a diesel particulate filter outlet mounting ring recessed toallow closer assembly of sub-systems, a flare ring coupling to eliminateplacement of the coupling in transition zone, a stackable sensor modulemount, tapered pressure sensor tubes to enable better water drainage,and/or a dual mounting sensor table.

II. Overview of Aftertreatment System

FIG. 1 depicts an aftertreatment system 100 having an example reductantdelivery system 110 for an exhaust system 190. The aftertreatment system100 includes a diesel particulate filter (DPF) 102, the reductantdelivery system 110, a decomposition chamber or reactor 104, a SCRcatalyst 106, and a sensor 150.

The DPF 102 is configured to remove particulate matter, such as soot,from exhaust gas flowing in the exhaust system 190. The DPF 102 includesan inlet, where the exhaust gas is received, and an outlet, where theexhaust gas exits after having particulate matter substantially filteredfrom the exhaust gas and/or converting the particulate matter intocarbon dioxide.

The decomposition chamber 104 is configured to convert a reductant, suchas an aqueous urea or diesel exhaust fluid (DEF), into ammonia. Thedecomposition chamber 104 includes a reductant delivery system 110having a dosing module 112 configured to dose the reductant into thedecomposition chamber 104. In some implementations, the reductant isinjected upstream of the SCR catalyst 106. The reductant droplets thenundergo the processes of evaporation, thermolysis, and hydrolysis toform gaseous ammonia within the exhaust system 190. The decompositionchamber 104 includes an inlet in fluid communication with the DPF 102 toreceive the exhaust gas containing NO_(x) emissions and an outlet forthe exhaust gas, NO_(x) emissions, ammonia, and/or remaining reductantto flow to the SCR catalyst 106.

The decomposition chamber 104 includes the dosing module 112 mounted tothe decomposition chamber 104 such that the dosing module 112 may dosethe reductant into the exhaust gases flowing in the exhaust system 190.The dosing module 112 may include an insulator 114 interposed between aportion of the dosing module 112 and the portion of the decompositionchamber 104 to which the dosing module 112 is mounted. The dosing module112 is fluidly coupled to one or more reductant sources 116. In someimplementations, a pump 118 may be used to pressurize the reductant fromthe reductant source 116 for delivery to the dosing module 112.

The dosing module 112 and pump 118 are also electrically orcommunicatively coupled to a controller 120. The controller 120 isconfigured to control the dosing module 112 to dose reductant into thedecomposition chamber 104. The controller 120 may also be configured tocontrol the pump 118. The controller 120 may include a microprocessor,an application-specific integrated circuit (ASIC), a field-programmablegate array (FPGA), etc., or combinations thereof. The controller 120 mayinclude memory which may include, but is not limited to, electronic,optical, magnetic, or any other storage or transmission device capableof providing a processor, ASIC, FPGA, etc. with program instructions.The memory may include a memory chip, Electrically Erasable ProgrammableRead-Only Memory (EEPROM), erasable programmable read only memory(EPROM), flash memory, or any other suitable memory from which thecontroller 120 can read instructions. The instructions may include codefrom any suitable programming language.

The SCR catalyst 106 is configured to assist in the reduction of NO_(x)emissions by accelerating a NO_(x) reduction process between the ammoniaand the NO_(x) of the exhaust gas into diatomic nitrogen, water, and/orcarbon dioxide. The SCR catalyst 106 includes inlet in fluidcommunication with the decomposition chamber 104 from which exhaust gasand reductant is received and an outlet in fluid communication with anend of the exhaust system 190.

The exhaust system 190 may further include a diesel oxidation catalyst(DOC) in fluid communication with the exhaust system 190 (e.g.,downstream of the SCR catalyst 106 or upstream of the DPF 102) tooxidize hydrocarbons and carbon monoxide in the exhaust gas.

In some implementations, the DPF 102 may be positioned downstream of thedecomposition chamber or reactor pipe 104. For instance, the DPF 102 andthe SCR catalyst 106 may be combined into a single unit, such as anSDPF. In some implementations, the dosing module 112 may instead bepositioned downstream of a turbocharger or upstream of a turbocharger.

The sensor 150 may be coupled to the exhaust system 190 to detect acondition of the exhaust gas flowing through the exhaust system 190. Insome implementations, the sensor 150 may have a portion disposed withinthe exhaust system 190, such as a tip of the sensor 150 may extend intoa portion of the exhaust system 190. In other implementations, thesensor 150 may receive exhaust gas through another conduit, such as asample pipe extending from the exhaust system 190. While the sensor 150is depicted as positioned downstream of the SCR catalyst 106, it shouldbe understood that the sensor 150 may be positioned at any otherposition of the exhaust system 190, including upstream of the DPF 102,within the DPF 102, between the DPF 102 and the decomposition chamber104, within the decomposition chamber 104, between the decompositionchamber 104 and the SCR catalyst 106, within the SCR catalyst 106, ordownstream of the SCR catalyst 106. In addition, two or more sensor 150may be utilized for detecting a condition of the exhaust gas, such astwo, three, four, five, or size sensor 150 with each sensor 150 locatedat one of the foregoing positions of the exhaust system 190.

The aftertreatment system 100 may be formed into an integratedaftertreatment system having one or more of the following features.

III. Example Sealed Connector Backshell

FIGS. 2-4 depict an example electrical connector backshell 200 having athin plastic two piece construction 210, 220 that may be susceptible toexposure to the environment. The electrical connector backshell 200houses an electrical connector 230 to which one or more electrical wires240 are coupled. In harsh conditions, the connector electrical contactsand component corrosion may occur and eventually result in failure ofthe connector and/or component. Some electrical connector backshells 200incorporate an exterior cover 250 formed from polyurethane, such as twopart elastofoam and elastocast, foam material which is injected as a twopart liquid into a mold that covers the harness and isolates theconnector 230 contacts from the environment. In some implementations,BASF 2 part elastofoam 4610/101 Resin and/or elastocast 70604TIsocyanate may be used. It may be useful to further seal the connectors230 by sealing the cavities for the contacts such that, when thepolyurethane foam is injected into the mold, the mold material issubstantially prevented from contaminating the connector 230 and/or theconnector electrical contacts, interfering with the locking mechanism ofthe connector, and/or interfering with the insertion of the connector230 into a mating connector. FIG. 5 depicts an example electricalconnector backshell 200 for such a sealing process.

The back side of the connector 230 is positioned within the electricalconnector backshell 200 and is sealed with a RTV sealant and allowed tocure. The electrical connector 230 is then coupled to one or moreelectrical wires and placed into a mold where the polyurethane isinjected. In some implementations, a RTV sealant seals the connection ofthe one or more electrical wires to the connector 230 as well. The RTVstops or substantially prevents the polyurethane from entering theconnector body 230 and/or the electrical connector backshell 200. Thetwo part polyurethane cures or hardens and is ready for installation onthe aftertreatment system. The final product is a wire harness that hasall the connectors 230 and/or electrical connector backshells 200 sealedfrom the environment because of the added RTV within the connector 230.In other implementations, sealing materials other than RTV may be usedto seal the connector 230, such as a sealant with a lower cure time fora faster manufacturing process.

IV. Example Variable Sizing

When a catalyst is canned during assembly, there may need to be aholding pressure applied to the catalyst. This pressure is exerted onthe catalyst from the mat material that sits between the catalyst andthe inner diameter of the body. The holding pressure is achieved bytargeting a specific mat density, referred to as the Gap Bulk Density(GBD). As a result of targeting a GBD level, the final body diameter mayvary for different manufactured parts. This final body diameter is afunction of the catalyst diameter, mat weight, and GBD tolerance range.Due to this variation in body diameter, it may be difficult to design acomponent to mate with this body as some parts may not fit over thebody, while others may have a gap that prevents or makes attachment moredifficult, such as difficulty in welding to cover the gap properly.Mating two components over a canned substrate may be useful to reducethe overall length of the system.

FIGS. 6-7 depict a catalyst component 300 and a mating flange 400 wherethe catalyst component 300 may have a variable diameter sizing 310 andthe mating flange 400 has a first constant diameter opening 410. Asdiscussed above, the catalyst component may have a diameter 310 thatvaries (e.g., varying by approximately ±3.4 mm in tolerance). Thediameter 310 of the catalyst component may vary as a function of thecatalyst diameter, a mat weight, a GBD, etc. However, with a firstconstant diameter for the opening 410 of the mating flange 400, thevarying catalyst component diameter may not properly align and/or fitinto the opening 410 of the mating flange 400. Accordingly, it may beuseful to size the diameter of the opening 410 of the mating flange 400and a portion of the catalyst component 300 to have constant sizeregardless of the varying diameter of the rest of the catalyst component300, as shown in FIG. 7.

As shown in FIG. 7, a casing of the aftertreatment system may include amating flange 400 with a first constant diameter opening 410. Thecatalyst component 300 is configured to mate to the mating flange 400 ofthe casing by being inserted into the first constant diameter opening410 of the mating flange 400. The catalyst component 300 includes acanned body 320 that has a first portion 322 sized to a second constantdiameter to mate with the first constant diameter opening 410 of themating flange 400 when the catalyst component 300 is inserted into themating flange 400. The first portion 322 may be a substantially smallportion of the canned body (e.g., 1-3 centimeters) relative to thelength of the catalyst component 300. The catalyst component 300includes a catalyst material 330 and a mat material 340 positionedwithin the canned body 320. The canned body 320 of the catalystcomponent 300 can be compressed, rolled, or otherwise reduced indiameter to form a second portion 324 sized to a third diameter, whichis less than the second constant diameter. In some instances, the thirddiameter has a tolerance of ±3.4 mm. The third diameter can be based ona holding pressure exerted on the catalyst material 330 by the matmaterial 340 when compressed within the canned body 320. In someimplementations, the holding pressure is based on a target Gap BulkDensity (GBD) for the mat material 340. In some implementations, thecanned body 320 includes a third portion 326 also sized to the thirddiameter and the first portion 322 is positioned between the secondportion 324 and the third portion 326.

Thus, the canned body 320 of the catalyst component 300 includes thefirst portion 322 as a region to which the mating flange 400 may becoupled based on the second contestant diameter of the first portion 322and the first constant diameter opening 410 of the mating flange 400.Thus, sizing the canned body 320 of the catalyst component 300 to aconstant diameter in the region where the canned body 320 joins themating flange 400 may assist in aligning and properly fitting thecatalyst component 300 to the mating flange 400. The remaining portionof the canned body 320 is then sized to the correct GBD target to ensureacceptable holding pressure is exerted on the catalyst material 330.

V. Example DPF Outlet Joint

FIG. 8 depicts an example separate joint ring 500 for a dieselparticulate filter (DPF) 600. A body joint may be needed at an outlet610 of the DPF 600 for coupling other components to the DPF 600,removing the DPF 600 for servicing, etc. However, an integrated jointmay increase the overall length of the aftertreatment system because theintegrated joint may extend beyond an end 602 of the DPF 600.Accordingly, it may be useful to create a separate diesel particulatefilter joint 500 that has the joint geometry (e.g., beading) on it thatmay be attached to a DPF outer casing 620 to align an end 502 of thediesel particulate filter joint 500 with the end 602 of the DPF 600,thereby reducing the length of the overall aftertreatment system.

The diesel particulate filter joint 500 includes a bead 510 for couplingthe DPF 600 to other components (e.g., via ring clamps or otherattachment methods). The diesel particulate filter joint 500 furtherincludes an attachment portion 520 for attaching the diesel particulatefilter joint 500 to the DPF outer casing 620 once the end 502 of thediesel particulate filter joint 500 is aligned with the end 602 of theDPF 600. The attachment portion 520 of the diesel particulate filterjoint 500 is welded to and over the DPF outer casing 620 to reduce theoverall length of the DPF 600 by permitting the bead 510 of the dieselparticulate filter joint 500 to be positioned over the DPF 600 withoutsubstantially adversely affecting the DPF material within the DPF outercasing 620. By locating the bead 510 over the DPF material, an overalllength of an integrated aftertreatment system can be reduced relative toan integrated joint. Such a reduction in overall system length, eitheralone or in combination with other features described herein, may permitalternative orientations and/or placements of the aftertreatment systemin a vehicle or other system.

VI. Example Flare Ring Coupling

FIGS. 9-10 depict an example transition portion 710 of an outer casing700 between a diesel oxidation catalyst (DOC) 750 and a dieselparticulate filter (DPF) 760 where the outer casing 710 changes indiameter from the DOC 750 to the DPF 760, such as the flare geometry 720shown in FIGS. 9-10. Due to the compact nature of an integratedaftertreatment system, high pressure and temperature couplings 730 mayneed to be located in the transition portion 710 of the outer casing700, which is the area where the body diameter varies from a smallerdiameter over the catalyst to a larger diameter at the body flareprofile between the DOC 750 and DPF 760. However, because of the varyingdiameter in the transition portion 710, it may be difficult to attachthe pressure and/or temperature coupling 730 during manufacture, such asdifficulty in obtaining a good weld, due to the curvature of thetransition portion 710. That is, because the size of the transitionportion 710 may vary for different manufactured parts, it may bedifficult to obtain a consistent weld between the couplings 730 and theouter casing 700.

FIGS. 11-12 depict an example flared ring 800 having a constant diameterfor a sensor coupling 830 to be attached. The flared ring 800 has aconstant diameter portion 810 to which the sensor coupling 830 iscoupled and/or fixed. The sensor coupling 830 may be welded and/orotherwise fixedly coupled to the constant diameter portion 810. Theflared ring 800 includes a flared portion 820 to transition to a largerdiameter for a downstream component and/or to be attached to the largerdiameter downstream component. A first component, such as the DPF 760,can be positioned within a first casing, such as casing 700. The flaredring 800 can then be fixedly coupled to the first casing at a first end802 of the flared ring 800. The constant diameter portion 810 of theflared ring 800 extends from the first end 802 to a flared portion 820at a second end 804 of the flared ring 800. In some implementations, thefirst end 802 of the flared ring 800 is welded to an outer portion ofthe first casing, such as a DPF body, to provide the sensor coupling 830and the attachment flare of the flared portion 820 for coupling to asecond casing having a second component positioned within the secondcasing, such as an upstream DOC 750. In some implementations, the sensorcoupling is a pressure and/or temperature coupling. The flared ring 800resolves the difficulty in attaching the sensor coupling 830 by allowingthe coupling to be welded to a flat, consistent body of the flared ring800. The flared ring 800 with the attached coupling subassembly is thenwelded to the canned DPF body in a final procedure.

VII. Example Integrated Sensor Harness and Module Alignment Component

In some situations, exhaust aftertreatment systems are a combination ofmultiple modules that contain catalyst coated substrates or mixers whereexhaust reagents are introduced. Furthermore, those modules may havevarious sensors mounted on the external housing. In order to minimizemanufacturing operations at a vehicle assembly plant, theseaftertreatment system sensors may be connected by a harness with asingle point for vehicle wiring harness connection.

FIGS. 13-14 depict an example integrated sensor harness and modulealignment component 900 coupled to a casing 992 of an integratedaftertreatment system 990 having a catalyst positioned within the casing992. The integrated sensor harness and module alignment component 900may operate as a sensor mount that is coupled to the casing 992 of theintegrated aftertreatment system 990. The integrated sensor harness andmodule alignment component 900 offers a low cost, robust solutionwithout adding extra components to an aftertreatment system. Theintegrated sensor harness and module alignment component 900 effectivelyaligns components while minimizing secondary operations by assemblypersonnel and service technicians.

The integrated sensor harness and module alignment component 900integrates a sensor harness 910 with rigid clipping points 920 ondifferent parts of an aftertreatment system. These clipping points 920on a rigid section of the sensor harness 910 allow positive alignment ofaftertreatment system modules and properly locate sensor mountingbrackets.

The harness 910 of the integrated sensor harness and module alignmentcomponent 900 may be comprised of bare wire, plastic conduit,chloroplast tape or polyurethane foam. In order to facilitateconnections to the sensor, certain sections of the sensor harness 910may be flexible enough to easily insert into the sensor. Furthermore, ifsensors are mounted on various parts of the aftertreatment system, itmay be advantageous to control the relative location of the varioussensor mounting brackets in order for them to be as close to nominallocation as possible. The integrated sensor harness and module alignmentcomponent 900 incorporates a rigid section of the sensor harness 910 andfixed mounting points 920 on the various sensor tables in order tocontrol the axial and radial location of the sensors, harness, andbrackets. These fixed mounting points 920 may include options such aszip ties or metal p-clips bolted on to brackets to affix the integratedsensor harness and module alignment component 900 to the casing 992and/or other mounting feature.

VIII. Example Stackable Sensor Mount

FIGS. 15-16 depict an example stackable sensor mount 1000 coupled to acasing 992 of an integrated aftertreatment system 990 having a catalystpositioned within the casing 992. The stackable sensor mount 1000includes one or more sensor mounting plates 1010 that may be tieredand/or oriented in any spatial orientation to accommodate one or moresensor modules. The sensor mounting plates 1010 can include two or moretiers such that multiple sensor modules may be mounted to the casing 992of the integrated aftertreatment system 990 at a single location. Bystacking the sensor modules in multiple tiers using the sensor mountingplates 1010, the footprint of required space for mounting sensor modulesfor the integrated aftertreatment system 990 may be reduced.

IX. Example Combination Bolt and/or Strap Mounted Sensor Table

FIGS. 17-19 depict an example combination bolt and/or strap mountedsensor table 1100. The combination bolt and/or strap mounted sensortable 1100 includes four bolt holes 1102 on four legs 1110 that can beused with regular bolts to mount the combination bolt and/or strapmounted sensor table 1100 on a casing 992 of an integratedaftertreatment system 990 having a catalyst positioned within the casing992. In addition, the combination bolt and/or strap mounted sensor table1100 includes a channel 1120 located at the bottom of the sensor table1100 to allow a band-clamp 1150 to be securely attached to mount thesensor table 1100 on the casing 992 of the integrated aftertreatmentsystem 990. In some implementations, both the bolts and the band-clampmay be used to attach the sensor table 1100 to the integratedaftertreatment system 990.

X. Example Tapered Pressure Sensor Tube

FIG. 20 depicts an example pressure sensor assembly having a pressuresensor 1200 with pressure tubes 1210, 1220 extending from a pressuresampling module of a casing 992 of an integrated aftertreatment system990 having a catalyst positioned within the casing 992. A diameter ofthe pressure tubes 1210, 1220 for the pressure sensor 1200 may beconstant. These constant diameter tubes 1210, 1220 (e.g., 7.94 mm innerdiameter) may not sufficiently drain out water that may condense in thetube. The water that condenses in the tubes 1210, 1220 may freeze andpotentially completely block the tubes 1210, 1220, thereby rendering thetubes 1210, 1220 incapable of correctly reading the exhaust pressure,deforming the tubes 1210, 1220, rupturing the tubes 1210, 1220, and/orcause other problems with the tubes 1210, 1220.

FIG. 21 depicts an example pressure sensor 1200 with a tapered diameterfor the pressure tubes 1230, 1240. The tapered pressure tubes 1230, 1240include a first end 1232, 1242 having a larger diameter near theintegrated aftertreatment system 990, which allows for increased waterdrainage out of the tapered tubes 1230, 1240. The tapered pressure tubes1230, 1240 include a second end 1234, 1244 near the pressure sensor 1200that have a smaller diameter to allow the tubes 1230, 1240 to beconnected to the pressure sensor 1200. The tapered pressure tubes' 1230,1240 diameter is smaller (e.g., 7.94 mm inner diameter) at the secondends 1234, 1244 to mate with a delta pressure sensor 1200 while thetapered pressure tubes' 1230, 1240 diameter is larger at the opposingfirst end 1232, 1242 (e.g., 13.9 mm inner diameter) to enable betterwater drainage out of the tubes 1230, 1240.

XI. Example Mold for Sealing an Electrical Connector

FIG. 22 depicts an example mold 1300 for sealing an electrical connectorfrom a curing mold material. The mold 1300 includes an upper moldportion 1310 and a lower mold portion 1320 such that, when the uppermold portion 1310 is closed and sealed to the lower mold portion 1320,polyurethane, such as a two part elastofoam and elastocast, foammaterial can be injected as a two part liquid into the mold 1300 to forma cover for a wiring harness to isolates contacts of a connector, suchas connector 230 of FIG. 2, from the environment. In someimplementations, BASF 2 part elastofoam 4610/101 Resin and/or elastocast70604T Isocyanate may be used.

The mold 1300 defines a first cavity 1302 to accommodate one or moreelectrical wires, such as electrical wires 240, and a second cavity 1304to accommodate an electrical connector backshell, such as electricalconnector backshell 200, and/or electrical connector, such as electricalconnector 230. As shown best in FIGS. 23A and 23B, the second cavity1304 includes an upper lip 1306 and a lower lip 1308 to form a smalltolerance opening 1310 between the first cavity 1302 and the secondcavity 1304 when the mold 1300 is closed and the one or more electricalwires are coupled to the electrical connector of the electricalconnector backshell. The second cavity 1304 is formed from an upperremovable component 1320 of FIG. 23A and a lower removable component1330 of FIG. 23B. The upper removable component 1320 includes the upperlip 1306 and the lower removable component 1330 including the lower lip1308. In some implementations, the upper removable component 1320 andthe lower removable component 1330 may be bolted or otherwise removablyattached to the mold 1300 such that the upper removable component 1320and the lower removable component 1330 may be replaced. For instance, ifthe upper lip 1306 or lower lip 1308 loses the small tolerance for thesmall tolerance opening 1310, then the upper removable component 1320 orlower removable component 1330 can be removed and replaced.

When the electrical harness is to be formed, the electrical connector isplaced in the second cavity 1304 of the mold 1300. The upper lip 1306and lower lip 1308 form a tight tolerance with the electrical wiresextending therethrough and substantially seals the back side of theconnector from polyurethane foam entering and contaminating theconnector. In such implementations, a sealed electrical harness can beformed without sealing the backside of the connectors with RTV or asimilar sealing product, thereby reducing manufacturing time andeliminating error for high volume production. However, in someimplementations, RTV or a similar sealing product may also still be usedto further seal the electrical connector.

While this specification contains many specific implementation details,these should not be construed as limitations on the scope of what may beclaimed, but rather as descriptions of features specific to particularimplementations. Certain features described in this specification in thecontext of separate implementations can also be implemented incombination in a single implementation. Conversely, various featuresdescribed in the context of a single implementation can also beimplemented in multiple implementations separately or in any suitablesubcombination. Moreover, although features may be described above asacting in certain combinations and even initially claimed as such, oneor more features from a claimed combination can in some cases be excisedfrom the combination, and the claimed combination may be directed to asubcombination or variation of a subcombination.

As utilized herein, the terms “approximately,” “about,” “substantially”,and similar terms are intended to have a broad meaning in harmony withthe common and accepted usage by those of ordinary skill in the art towhich the subject matter of this disclosure pertains. It should beunderstood by those of skill in the art who review this disclosure thatthese terms are intended to allow a description of certain featuresdescribed and claimed without restricting the scope of these features tothe precise numerical ranges provided. Accordingly, these terms shouldbe interpreted as indicating that insubstantial or inconsequentialmodifications or alterations of the subject matter described and claimedare considered to be within the scope of the invention as recited in theappended claims. Additionally, it is noted that limitations in theclaims should not be interpreted as constituting “means plus function”limitations under the United States patent laws in the event that theterm “means” is not used therein.

The terms “coupled,” “connected,” and the like as used herein mean thejoining of two components directly or indirectly to one another. Suchjoining may be stationary (e.g., permanent) or moveable (e.g., removableor releasable). Such joining may be achieved with the two components orthe two components and any additional intermediate components beingintegrally formed as a single unitary body with one another or with thetwo components or the two components and any additional intermediatecomponents being attached to one another.

The terms “fluidly coupled,” “in fluid communication,” and the like asused herein mean the two components or objects have a pathway formedbetween the two components or objects in which a fluid, such as water,air, gaseous reductant, gaseous ammonia, etc., may flow, either with orwithout intervening components or objects. Examples of fluid couplingsor configurations for enabling fluid communication may include piping,channels, or any other suitable components for enabling the flow of afluid from one component or object to another.

It is important to note that the construction and arrangement of thesystem shown in the various exemplary implementations is illustrativeonly and not restrictive in character. All changes and modificationsthat come within the spirit and/or scope of the describedimplementations are desired to be protected. It should be understoodthat some features may not be necessary and implementations lacking thevarious features may be contemplated as within the scope of theapplication, the scope being defined by the claims that follow. Inreading the claims, it is intended that when words such as “a,” “an,”“at least one,” or “at least one portion” are used there is no intentionto limit the claim to only one item unless specifically stated to thecontrary in the claim. When the language “at least a portion” and/or “aportion” is used the item can include a portion and/or the entire itemunless specifically stated to the contrary.

1. An integrated aftertreatment system comprising: a casing comprising amating flange having a first constant diameter opening; and a catalystcomponent configured to mate to the mating flange of the casing, whereinthe catalyst component comprises a catalyst material, a mat material,and a canned body, the canned body including a first portion sized to asecond constant diameter to mate with the first constant diameteropening of the mating flange and a second portion sized to a thirddiameter based on a holding pressure exerted on the catalyst material bythe mat material.
 2. (canceled)
 3. The integrated aftertreatment systemof claim 1, wherein the holding pressure is based on a target gap bulkdensity for the mat material.
 4. The integrated aftertreatment system ofclaim 1, wherein the third diameter is less than the second constantdiameter.
 5. The integrated aftertreatment system of claim 1, whereinthe third diameter has a tolerance of ±3.4 mm.
 6. The integratedaftertreatment system of claim 1, wherein the canned body comprises athird portion sized to the third diameter, the first portion positionedbetween the second portion and the third portion.
 7. The integratedaftertreatment system of claim 1, wherein the second portion of thecanned body of the catalyst component is upstream of the first portion.8. The integrated aftertreatment system of claim 1, wherein the secondportion of the canned body of the catalyst component is downstream ofthe first portion.
 9. An integrated aftertreatment system comprising: aparticulate filter having an outer casing with an outlet; and aparticulate filter joint coupled to the outer casing of the particulatefilter at the outlet, an end of the particulate filter joint alignedwith an end of the particulate filter.
 10. The integrated aftertreatmentsystem of claim 9, wherein the particulate filter joint comprises abead.
 11. The integrated aftertreatment system of claim 9, wherein theparticulate filter joint is welded to the outer casing of theparticulate filter.
 12. The integrated aftertreatment system of claim 9,wherein the particulate filter joint reduces an overall length of theintegrated aftertreatment system relative to an integrated joint.
 13. Anintegrated aftertreatment system comprising: a first casing; a firstcomponent positioned within the first casing; a second casing; a secondcomponent positioned within the second casing; and a flared ring fixedlycoupled to the first casing at a first end and coupled to the secondcasing at a second end opposite the first end, the flared ring having aconstant diameter portion extending from the first end to a flaredportion at the second end, the flared ring including a sensor couplingfixed to the constant diameter portion.
 14. The integratedaftertreatment system of claim 13, wherein the sensor coupling comprisesa pressure coupling or a temperature coupling.
 15. The integratedaftertreatment system of claim 13, wherein the first component is adiesel oxidation catalyst and the second component is a particulatefilter.
 16. The integrated aftertreatment system of claim 13, whereinthe flared ring is welded to an outer portion of the first casing. 17.An integrated aftertreatment system comprising: a casing; a catalystpositioned within the casing; and a sensor mount coupled to an outerportion of the casing.
 18. The integrated aftertreatment system of claim17, wherein the sensor mount is an integrated sensor harness and modulealignment component, the integrated sensor harness and module alignmentcomponent including rigid attachment points to couple to the outerportion of the casing.
 19. The integrated aftertreatment system of claim17, wherein the sensor mount comprises two or more tiers.
 20. Theintegrated aftertreatment system of claim 17, wherein the sensor mountcomprises both attachment openings and a strap attachment channel. 21.An integrated aftertreatment system comprising: a casing; a catalystpositioned within the casing; and a pressure sensor assembly coupled tothe casing, the pressure sensor assembly having a tapered tube coupledat a first end to a pressure sensor module and coupled at a second endto a coupling of the casing, the first end having a smaller diameterthan the second end.
 22. The integrated aftertreatment system of claim21, wherein the tapered tube is configured to drain water out from thetapered tube.
 23. An integrated aftertreatment system comprising: acasing; a catalyst positioned within the casing; and an electricalconnector having a sealant within a backshell of the electricalconnector.
 24. The integrated aftertreatment system of claim 23, whereinthe sealant is RTV.
 25. The integrated aftertreatment system of claim23, wherein the backshell of the electrical connector is formed frompolyurethane.
 26. A mold for sealing an electrical connector from acuring mold material, the mold comprising: a first cavity for anelectrical wire; and a second cavity for an electrical connector, thesecond cavity including an upper lip and a lower lip to form a smalltolerance opening between the first cavity and the second cavity whenthe mold is closed and the electrical wire is coupled to the electricalconnector.
 27. The mold of claim 26, wherein the second cavity is formedfrom an upper removable component and a lower removable component, theupper removable component including the upper lip and the lowerremovable component including the lower lip.